Magnesia Brick (Fused)
Main Chemical Compositions & Categories
Fused Magnesia Bricks are composed of high-purity, crystalline MAGNESIUM OXIDE (MgO), typically 98% to 99% purity. The material is produced via the Fusion Casting process, which involves melting MgO raw material at 2800°C and then solidifying it to form a dense, zero-porosity product.
| CATEGORY | MgO CONTENT | BONDING/MATRIX | PRIMARY ADVANTAGE |
| FUSED MgO | $98% to 99% | Fusion-Cast (Zero Porosity) | Maximum resistance to chemical corrosion/penetration |
| DEAD BURNED MgO | 980% to 95% | Ceramic (Sintered) | Cost-effective general basic refractory |
Key Properties and Performance
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Apparent Porosity (AP) | NEGLIGIBLE (< 1%) | Fusion eliminates all open porosity, preventing slag/metal infiltration. |
| Crystal Size | EXTREMELY LARGE | Large periclase crystals provide maximum resistance to chemical attack and high T creep. |
| Creep in Compression (CISC) | EXTREMELY LOW | Maximum density and purity ensure minimal deformation under constant load at the highest temperatures. |
| Slag Resistance | ULTIMATE (to BASIC Slags) | Zero porosity and high purity maximize stability against CaO– and MgO-saturated melts. |
Advantages and Key Characteristics
Fused Magnesia bricks represent the highest tier of basic refractory performance, justified only in areas of extreme chemical attack, high heat flux, and critical load.
- Maximum Infiltration Resistance: The fusion-casting process results in a theoretical zero-porosity structure. This completely seals the brick against penetration by molten steel, slag, and corrosive gases, which is the primary failure mechanism for sintered refractories.
- Superior Hot Strength and Creep: The large, interlocking periclase crystals formed during slow cooling from the melt provide unrivaled load-bearing capacity and resistance to long-term deformation at near-melting temperatures (TUL).
- Chemical Purity: The high-purity MgO ensures minimal contamination of the molten charge and prevents the formation of low-melting silicate phases, which are detrimental to hot strength.
Typical Industries and Applications
This brick is used in critical, high-stress, and continuous operation zones in metallurgy:
- Ferrous Industry (Steel): Hot spots and critical containment areas in Electric Arc Furnaces (EAFs), Ladle Refining Furnaces (LRFs), and Vacuum Degassers (VD) where maximum campaign life is demanded.
- Non-Ferrous Industry: Refining vessels and specialized kilns handling highly aggressive basic slags.
- Continuous Casting: Specialized wear-resistant components.
Furnace Areas and Service Zones
They are specified for high-wear zones that demand integrity over long periods:
- EAF SLAG LINE/HOT SPOTS: Used to maximize refractory life in areas subject to the highest thermal and chemical load.
- VD/LRF BOTTOM AND WALLS: Used to ensure clean, contamination-free refining and long life under vacuum conditions.
- PERMANENT SAFETY LININGS: Used as a protective layer beneath the working lining in critical vessels.
Key Data Sheet Properties to Consider
Selection is focused on density and purity as direct results of the fusion process:
- MgO Purity: 98% or higher is required to qualify as a premium fused product.
- Bulk Density (BD): CRITICAL VALUE. Must be exceptionally high (e.g., 3.4 g/cm3 or greater) to confirm the zero-porosity structure.
- Apparent Porosity (AP): Must be reported as < 1.0% (ideally $< 0.5%) to confirm maximum infiltration resistance.
- Crystal Size: Look for large crystal sizes (e.g., > 100 microns), which directly translate to superior corrosion resistance.
Technical Guidance: Fused Magnesia is the most expensive basic refractory and is justified only for the most severe applications where the cost of failure outweighs the material cost. Due to its extreme density and rigidity, Fused MgO has POOR THERMAL SHOCK RESISTANCE. It requires a very slow and controlled heat-up/cool-down schedule, and it is generally unsuitable for highly cyclic furnaces unless protected by a lining with better thermal shock properties (e.g., MgO-C).
✨ Customization Services
We offer product customization services, allowing you to tailor the appearance, dimensions, or specific markings of items like refractory shapes or bricks. This includes options for incorporating specific geometric requirements to ensure seamless integration into your process systems.
🔬 Sampling for Testing & Validation
Free product samples are available for thorough testing and validation. This allows you to confirm the quality, compatibility, and performance of our materials—such as specific bricks, castables, or raw materials—before committing to a full order.
💡 Expertise in Refractory Solutions
Leverage our deep expertise to receive detailed, application-specific refractory solutions. We move beyond just selling products by providing comprehensive plans that encompass material selection, installation guidance, and performance optimization to maximize the lifespan and efficiency of your high-temperature processes.
Rabatec products are exclusively manufactured in facilities that have achieved rigorous ISO certifications across Quality (ISO 9001), Environmental Management, and Occupational Health & Safety. This commitment ensures every product, from refractory bricks to specialized equipment, meets the highest global benchmarks for performance, sustainability, and workplace safety.
📦 Logistics Excellence: Shipping, Packaging, and Marking
Minimizing Risk: We manage all logistics to minimize handling touchpoints and transit shock. Our carriers are pre-vetted for their experience in transporting heavy, fragile, and sensitive industrial materials.
Traceability: Every shipment includes comprehensive documentation and tracking information, providing end-to-end visibility and ensuring precise delivery coordination for your site.
Protection is Paramount: Our packaging strictly follows industry standards to prevent damage, corner chipping, and moisture absorption—especially critical for materials like Basic Refractory Bricks and Refractory Mortars & Mixes.
Robust Palletization: Products are secured on fumigated, high-strength export pallets (e.g., 1100x950mm or similar sturdy dimensions) using heavy-duty strapping and durable protective wrapping (polyethylene sheeting, cardboard, etc.) to withstand long-distance travel and multiple loadings.
Moisture Control: Sensitive materials are protected with appropriate sealing and, where necessary, desiccants or moisture-vapor proof enclosures to maintain the product's integrity until installation.
Clear Identification: All outer packaging is clearly marked on multiple sides with large, legible text for immediate identification and safe handling.
Full Traceability: Markings include all essential data points: Product Name, Quality Grade, Batch Number, Quantity, Net/Gross Weight, Order Number, and the Final Destination/Construction Area. This ensures every pallet can be accounted for and correctly staged upon arrival.
Safety & Compliance: We adhere to all regulatory requirements for marking, labeling, and placarding—especially for any items classified as Dangerous Goods—to ensure full compliance with international and domestic transport regulations.
❓ Frequently Asked Questions (FAQ)
Question | Elaborated Answer |
Q: What is the Refractoriness Under Load (RUL) of your refractories? | A: Refractoriness Under Load (RUL) is a critical property that defines the maximum temperature our materials can withstand while under compressive stress before deforming (softening). Since we offer a wide range of materials—from Alumina-Silicate Bricks to high-performance Silicon Carbide Bricks—the RUL varies significantly. For specific product data, please refer to the product data sheet or submit a quote request for the material you are interested in. |
Q: Where are the Rabatec refractories and materials produced? | A: Our products are primarily sourced from specialized manufacturing plants in China. Crucially, these facilities have all undergone rigorous audits and achieved comprehensive ISO certifications (Quality, Environment, and Safety), ensuring that production adheres to the highest global standards for consistency and performance. |
Q: What refractory materials does the company offer? | A: We supply a comprehensive portfolio of advanced refractory solutions, including: Shaped Products: Alumina & Silica Bricks, Basic & Specialized Bricks (e.g., Magnesia), SiC & Structural Ceramics, and Precast Shapes. Monolithic Products: Refractory Castables, Mixes & Mortars. Insulation: Insulation Fibre and High-Performance Insulation Products. |
Q: How should I choose the appropriate refractory material for my application? | A: Selecting the correct refractory is paramount to process efficiency. The choice depends on three key factors: 1. Operating Environment: Maximum process temperature and thermal cycling (shock). 2. Chemical Attack: Type of slag, molten metal, or corrosive gas being handled (acidic, neutral, or basic). 3. Mechanical Stress: Abrasion, erosion, and static load requirements. We recommend utilizing our detailed refractory solutions service to consult with our engineers for an optimized, application-specific recommendation. |
Q: Which monolithic material should I choose when patching an existing lining? | A: For patching and minor repairs, the ideal monolithic material depends on the parent lining material, the patching depth, and the need for a rapid return to service. Common choices include: Refractory Mortars & Mixes (for minor joints/surfaces) or Plastic Refractories (for areas requiring physical compaction). Always choose a patch material chemically compatible with the existing lining to ensure proper bonding and service life. |
Q: Can I receive product samples before placing a major order? | A: Yes. We gladly provide product samples for your internal testing and validation purposes. This ensures you can confirm the quality, composition, and fit of the material—such as our Refractory Castables or Alumina-Silicate Bricks—in your specific operational environment before committing to a bulk purchase. |
Q: Do you provide certifications to verify material quality? | A: Absolutely. We provide product-related inspection certificates and quality assurance documentation upon request. This verifies that your order has passed all internal quality control checks and meets the required material specifications and industry standards. |
Q: What measures are taken for product protection during transport? | A: We ensure quick, reliable transport by using robust, industrial packaging that strictly follows industry standards. This includes high-strength palletization, heavy-duty strapping, and weather-resistant wrapping to protect fragile items like bricks and mixes from corner chipping, mechanical damage, and moisture during transit. |
